Substrate processing apparatus, substrate processing method, and storage medium

ABSTRACT

There is provided a substrate processing apparatus which includes: a substrate mounting table installed in a vacuum vessel; a gas supply part configured to supply a processing gas into the vacuum vessel; a vacuum-exhausting part configured to exhaust the interior of the vacuum vessel; an elevating member configured to lift up and down a substrate while holding the substrate mounted on the mounting table; and a control part configured to output a control signal to execute a first step of supplying the processing gas onto the substrate and setting an internal pressure of the vacuum vessel to a first pressure, a second step of changing the internal pressure to a second pressure lower than the first pressure, and a third step of lifting up the substrate from the mounting table after the first step and before the second step or in parallel with the second step.

CROSS-REFERENCE TO RELATED APPLICATION

This application claims the benefit of Japanese Patent Application No.2015-028939, filed on Feb. 17, 2015, in the Japan Patent Office, thedisclosure of which is incorporated herein in its entirety by reference.

TECHNICAL FIELD

The present disclosure relates to a technique of performing a process ona substrate by supplying a processing gas onto the substrate in a vacuumatmosphere.

BACKGROUND

In a semiconductor manufacturing process, in order to reduce resistanceof a contact portion between wirings formed in a semiconductor wafer(hereinafter, simply referred to as a “wafer”), there is a process offorming a titanium (Ti) film on an inner side of a hole and nitriding asurface of the Ti film, prior to filling of the hole with metal.

For example, the Ti film is formed by a CVD (Chemical Vapor Deposition)method in which a wafer is mounted on a mounting table serving also as alower electrode installed inside a chamber and a processing gas issupplied from a shower head serving also as an upper electrode whilemaintaining the interior of the chamber at a predetermined degree ofvacuum. Thereafter, for example, a high frequency is applied to theshower head so as to generate plasma such that the processing gas isactivated to cause a chemical reaction. Reaction products thus generatedare deposited on a surface of the wafer to form the Ti film.

The Ti film is formed by supplying, for example, a TiCl₄ gas and an H₂gas as the processing gases into the chamber and plasmarizing thesegases. In addition, a nitriding process for the surface of the Ti filmis performed by supplying a nitriding gas, e.g., an NH₃ gas, into thechamber.

After the nitriding process is completed, an internal pressure of thechamber is reduced to discharge the NH₃ gas from the chamber. At thistime, it is observed that a wafer sliding phenomenon that the waferslides on the surface of the mounting table occurs. This peels off athin film deposited on the surface of the mounting table by a frictioncaused by the wafer sliding, which may result in the occurrence ofparticles.

In a plasma process, a metal mechanical chuck cannot be used to preventan abnormal discharge at the time of generating plasma. In addition, ina process at a high temperature of 400 degrees C. or more, anelectrostatic chuck cannot be used since the process temperature exceedsa heat-resistant temperature. Therefore, a chuck cannot be used toprevent the wafer from sliding.

In addition, the present inventors have made studies on increasing thefilm thickness by repeating a Ti film forming process and a nitridingprocess a multiple number of times. In this case, there is a possibilitythat a wafer sliding phenomenon occurs every time an NH₃ gas isdischarged from a chamber, which may result in a poor in-planeuniformity of film thickness in addition to the occurrence of particles.

For example, there is known a configuration in which a guide ring forguiding a wafer is installed in a periphery of a surface of a mountingtable. In such a configuration, a movement range of the wafer isrestricted even if a wafer sliding phenomenon occurs during a filmforming process. As such, the wafer can be transferred between anexternal transfer mechanism and the mounting table. However, if thewafer is slid to make contact with the guide ring, a thin film depositedon the guide ring may be peeled off, which may result in the occurrenceof particles. In addition, if the wafer is slid to be too close to theguide ring, a deviation in concentration distribution of a film-forminggas may be generated. This degrades an in-plane uniformity of filmthickness and partially increases contamination of a rear surface of thewafer.

In addition, there is known an example in which a nitriding process isperformed with a plasmarized nitrogen gas in a state where a wafer islifted up to be spaced apart from a mounting table by a predetermineddistance. In this example, a peripheral portion of a rear surface of thewafer is in contact with plasma so that active species contributing tothe nitriding process are increased in a periphery of a front surface ofthe wafer. This decreases a difference in the amount of nitrogenintroduced between the central portion and the periphery of the wafer,thereby achieving the nitriding process with high in-plane uniformity.However, since this example does not take into consideration the slidingof the wafer mounted on the mounting stable during the nitridingprocess, it is difficult to address the issues related to the presentdisclosure.

SUMMARY

Some embodiments of the present disclosure provide a technique ofpreventing a substrate mounted on a mounting table from being slid dueto a pressure variation, in performing a process on a substrate bysupplying a processing gas onto the substrate in a vacuum atmosphere.

According to one embodiment of the present disclosure, there is provideda substrate processing apparatus of performing a process on a substrateby supplying a processing gas onto the substrate in a vacuum atmosphere,including: a substrate mounting table installed in a vacuum vessel; agas supply part configured to supply the processing gas into the vacuumvessel; a vacuum-exhausting part configured to exhaust the interior ofthe vacuum vessel; an elevating member configured to move up and downbetween an ascending position defined above a surface of the mountingtable and a descending position equal to or lower than a level of thesurface of the mounting table and is configured to lift up and down thesubstrate while holding the substrate mounted on the mounting table; anda control part configured to output a control signal to execute a firststep, a second step and a third step, the first step being to supply theprocessing gas onto the substrate mounted on the mounting table and setan internal pressure of the vacuum vessel to a first pressure, thesecond step being to change the internal pressure to a second pressurelower than the first pressure, and the third step being to lift up thesubstrate from the mounting table by the elevating member after thefirst step and before the changing the internal pressure or in parallelwith the changing.

According to another embodiment of the present disclosure, there isprovided a method of processing a substrate by supplying a processinggas onto the substrate in a vacuum atmosphere. The method includes:mounting the substrate on a mounting table installed in a vacuum vessel;supplying the processing gas onto the substrate mounted on the mountingtable and setting an internal pressure of the vacuum vessel to a firstpressure; subsequently, changing the internal pressure to a secondpressure lower than the first pressure; and after the supplying theprocessing gas, lifting up the substrate from the mounting table by anelevating member before the changing the internal pressure or inparallel with the changing.

According to yet another embodiment of the present disclosure, there isprovided a non-transitory computer-readable storage medium that stores acomputer program used for a substrate processing apparatus of performinga process on a substrate by supplying a processing gas onto thesubstrate mounted on a mounting table in a vacuum vessel whilemaintaining a vacuum atmosphere, wherein the computer program isorganized with instructions for executing the aforementioned method.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings, which are incorporated in and constitute apart of the specification, illustrate embodiments of the presentdisclosure, and together with the general description given above andthe detailed description of the embodiments given below, serve toexplain the principles of the present disclosure.

FIG. 1 is a longitudinal sectional view showing a substrate processingapparatus according to an embodiment of the present disclosure.

FIG. 2 is a longitudinal sectional view showing a substrate processingapparatus according to an embodiment of the present disclosure.

FIG. 3 is a longitudinal sectional view showing a substrate processingapparatus according to an embodiment of the present disclosure.

FIG. 4 is a longitudinal sectional view showing a substrate processingapparatus according to an embodiment of the present disclosure.

FIG. 5 is a process view showing an example of a film forming processperformed in the substrate processing apparatus.

FIG. 6 is a characteristic view showing a result of an evaluation test.

FIG. 7 is a characteristic view showing a result of an evaluation test.

FIG. 8 is a characteristic view showing a result of an evaluation test.

DETAILED DESCRIPTION

Hereinafter, an example of a configuration of a substrate processingapparatus according to an embodiment of the present disclosure will bedescribed with reference to FIG. 1. In the following detaileddescription, numerous specific details are set forth in order to providea thorough understanding of the present disclosure. However, it will beapparent to one of ordinary skill in the art that the present disclosuremay be practiced without these specific details. In other instances,well-known methods, procedures, systems, and components have not beendescribed in detail so as not to unnecessarily obscure aspects of thevarious embodiments.

A substrate processing apparatus 1 is to form a film such as a Ti filmby a plasma CVD, and includes an airtight cylindrical vacuum vessel 2.For example, a downward-protruding cylindrical exhaust chamber 21 isformed in the central portion of a bottom wall of the vacuum vessel 2.An exhaust path 22 is connected to a lateral side of the exhaust chamber21. The exhaust path 22 is coupled to a vacuum-exhausting part 24 via apressure adjusting part 23 equipped with a pressure adjusting valve suchas a butterfly valve, so that the interior of the vacuum vessel 2 isdepressurized up to a predetermined degree of vacuum. In addition, atransfer port 25 through which a wafer W is transferred between thevacuum vessel 2 and a transfer chamber (not shown), is formed in alateral side of the vacuum vessel 2. The transfer port 25 is configuredto be opened and closed by a gate valve 26.

A mounting table 3 configured to hold the wafer W in a substantiallyhorizontal posture is installed inside the vacuum vessel 2. For example,the mounting table 3 is supported by a cylindrical support member 31 atthe central portion of a lower surface thereof. The mounting table 3 ismade of ceramics such as aluminum nitride (AlN) and has an upper surfacecoated with a material such as nickel (Ni). An arithmetic averagesurface roughness of the upper surface of the mounting table 3 is setto, e.g., 10 μm or more. A guide ring 32 configured to guide the wafer Wis disposed in the periphery of the upper surface of the mounting table3. In some embodiments, the mounting table 3 may be made of ceramics ofthe aluminum nitride alone or may be made entirely of a metal materialsuch as nickel.

The arithmetic average surface roughness (hereinafter, simply referredto as an “average surface roughness Ra”) represents a value obtained byextracting a reference length of 1 from a roughness curve in a directionof its average line, taking an X axis in the direction of the averageline of the reference length of 1 and a Y axis in a direction oflongitudinal magnification, summing absolute values of deviations ofmeasurement curves which are deviated from the average line of thereference length of 1, and averaging the absolute values. When theroughness curve is expressed by y=f(x), the average surface roughness Rais derived according to the following equation.

${Ra} = {\frac{1}{}{\int_{0}^{}{{{f(x)}}\ {x}}}}$

In addition, the mounting table 3 includes, for example, a groundedlower electrode 33 embedded therein and a heating mechanism 34 disposedbelow the lower electrode 33. Based on a control signal from a controlpart 100 to be described later, a power supply (not shown) applies powerto the lower electrode 33 and the heating mechanism 34 so that the waferW is heated at a preset temperature, e.g., 400 degrees C. or higher.Further, if the mounting table 3 is made entirely of metal, it is notnecessary to embed the lower electrode 33 in the mounting table 3 sincethe entire mounting table 3 acts as the lower electrode.

In addition, three or more (e.g., three) lifting pins 41 as a liftingmember configured to lift up and down the wafer W while supporting thewafer W mounted on the mounting table 3 are installed in the mountingtable 3. These lifting pins 41 are made of, for example, ceramics suchas alumina (Al₂O₃), or quartz. Lower ends of the lifting pins 41 areattached to a common support plate 42. The common support plate 42 iscoupled to a lifting mechanism 44 formed of, e.g., an air cylinder,which is installed outside the vacuum vessel 2, via a lifting shaft 43.

For example, the lifting mechanism 44 is installed below the exhaustchamber 21. An opening 211 through which the lifting shaft 43 passes, isformed in the bottom of the exhaust chamber 21. A bellows 45 isinstalled between the opening 211 and the lifting mechanism 44. Inaddition, the support plate 42 is formed in a shape which is verticallymovable without interfering with the support member 31 of the mountingtable 3. Thus, the lifting pins 41 are configured to move up and down bythe lifting mechanism 44 between a lifting-up position at which thelifting pins 41 protrude upward from the upper surface of the mountingtable 3 and a lifting-down position which is equal to or lower than alevel of the upper surface of the mounting table 3.

Examples of the lifting-up position may include a transfer position atthe time of transferring the wafer between an external transfermechanism and the mounting table 3 (a position of the wafer W shown inFIG. 2) and an ascending position at which the wafer W is lifted up fromthe upper surface of the mounting table 3 when an internal pressure ofthe vacuum vessel 2 is changed as described later (a position of thewafer W shown in FIG. 4). The following description will be made on theassumption of that the position shown in FIG. 2 is the transfer positionand the position shown in FIG. 4 is the ascending position. A positionat which the wafer W is mounted on the mounting table 3 refers to adescending position, as shown in FIGS. 1 and 3.

A gas supply part 5 used as an upper electrode is installed in a ceilingwall 27 of the vacuum vessel 2 with an insulating member 28 interposedbetween the ceiling wall 27 and the gas supply part 5. The gas supplypart 5 is coupled to a high frequency power supply 51 via a matchingdevice 511. When a high frequency (RF) of, e.g., 450 kHz is applied fromthe high frequency power supply 51 to the gas supply part 5, a highfrequency electric field is generated between the upper electrode as thegas supply part 5 and the lower electrode 33.

The gas supply part 5 includes a hollow gas supply chamber 52. Aplurality of holes 53 through which a processing gas is dispersivelysupplied into the vacuum vessel 2, is formed in a bottom surface of thegas supply chamber 52 at regular intervals, for example. Further, thegas supply part 5 includes a heating mechanism 54 embedded therein, forexample, above the gas supply chamber 52. Based on a control signal fromthe control part 100 described later, power is applied from a powersupply (not shown) to the heating mechanism 54 so that the heatingmechanism 54 is heated to a preset temperature.

A gas supply path 6 is installed in the gas supply chamber 52. Aplurality of gas supply sources 61 to 64 is connected to an upstreamportion of the gas supply path 6. In this embodiment, the gas supplysource 61 is to supply a TiCl₄ as a Ti compound gas, the gas supplysource 62 is to supply a hydrogen (H₂) gas as a reducing gas, the gassupply source 63 is to supply an ammonia (NH₃) gas as a nitriding gas,and the gas supply source 64 is to supply an argon (Ar) gas. In thisembodiment, the TiCL₄ gas and the H₂ gas correspond to a film-forminggas. The film-forming gas and the nitriding gas are referred to as a“processing gas.”

These gas supply sources 61 to 64 are coupled to the gas supply path 6through supply paths 611, 621, 631 and 641, respectively. The supplypaths 611, 621, 631 and 641 include valves V1 to V4 and mass flowcontrollers M1 to M4, respectively. Each of the valves V1 to V4 and eachof the mass flow controllers M1 to M4 are configured to control a flowrate of gas and supply/shut off operations of the gas, based on acontrol signal Q provided from the control part 100, which will bedescribed later.

The substrate processing apparatus 1 is provided with the control part100 including a computer configured to control the entire operation ofthe apparatus 1. The control part 100 includes a program storage part101 to store a program for executing a film forming process (which willbe described later). The term “program” used herein may include softwaresuch as a processing recipe. This program is to send control signals torespective components of the apparatus 1 so as to control operations ofthe respective components. The program is organized with instructionsfor executing various processes (which will be described later). Theprogram is installed from a storage medium such as a hard disk, acompact disc, a magneto-optic disk, a memory card, a flexible disk orthe like, in the control part 100. In addition, the program storage part101 stores a program for outputting control signals to execute a firststep, a second step and a third step (which will be described later) anda program for outputting a control signal to repeat a sequence of thefirst and second steps a multiple number of times.

The first step is to supply the processing gas onto the wafer W mountedon the mounting table 3 and to set the internal pressure of the vacuumvessel 2 to a first pressure. The second step is to change the internalpressure of the vacuum vessel 2 to a second pressure lower than thefirst pressure, after the first step. The third step is to change theinternal pressure of the vacuum vessel 2 and simultaneously to lift upthe wafer W from the mounting table 3 by the lifting pins 41, after thefirst step.

Next, the film forming process performed in the substrate processingapparatus 1 will be described with reference to FIGS. 2 to 5. FIG. 5schematically shows a state where the processing gas such as the TiCL₄gas and so on, the internal pressure of the vacuum vessel 2 and theheight of the lifting pins 41 are changed as the film forming processproceeds. In FIG. 5, a horizontal axis represents a timeline which issegmented for ease of illustration, regardless of an actual processingtime.

As for the processing gas, a state where the processing gas is beingsupplied into the vacuum vessel 2 is referred to as an “ON” state and astate where the supply of the processing gas is stopped is referred toas an “OFF” state. As for the internal pressure of the vacuum vessel 2,only the first pressure and the second pressure are shown, but pressuresat the time of introducing the TiCl₄ gas and unloading the wafer areomitted. A height position of the lifting pins 41 is assumed to includethree positions: the transfer position, the ascending position and thedescending position.

First, as shown in FIG. 2, the wafer W is loaded into the vacuum vessel2 by the external transfer mechanism (not shown) and subsequently, thelifting pins 41 are raised up to the transfer position such that thewafer W is delivered on the lifting pins 41 from the external transfermechanism. Thereafter, the external transfer mechanism is lowered andthe lifting pins 41 are moved down to the descending position as shownin FIG. 3 so that the wafer W is mounted on the mounting table 3.Meanwhile, once the external transfer mechanism is lowered, the gatevalve 26 is closed and the first step is performed in the vacuum vessel2.

The mounting table 3 and the gas supply part 5 have been already heatedby the heating mechanisms 34 and 54, respectively, so that the wafer Wis heated to a temperature of 400 degrees C. or higher when it ismounted on the mounting table 3. An example of a process temperature ofthe wafer W may include 450 degrees C. In addition, the interior of thevacuum vessel 2 is set to a preset pressure by the vacuum-exhaustingpart 24. Subsequently, as shown in FIGS. 3 and 5, the TiCl₄ gas, the H₂gas and the Ar gas as the film-forming gas are supplied into the vacuumvessel 2 via the gas supply part 5, and the high frequency power supply51 applies a high frequency power to the gas supply part 5 based on acontrol signal P provided from the control part 100. Thus, a parallelflat electrode constituted by the upper electrode used as the gas supplypart 5 and the lower electrode 33 is formed, generatingcapacitively-coupled plasma. As a result, the TiCl₄ gas and the H₂ gasare activated to react with each other so that a Ti film is formed on asurface of the wafer W.

Subsequently, as shown in FIG. 5, the supply of the TiCl₄ gas, the H₂gas and the Ar gas is stopped and the application of the high frequencypower to the gas supply part 5 is also stopped. Further, the interior ofthe vacuum vessel 2 is exhausted to discharge the TiCl₄ gas, the H₂ gasand the Ar gas therefrom.

Thereafter, the internal pressure of the vacuum vessel 2 is set to thefirst pressure, and the H₂ gas, the NH₃ gas and the Ar gas are suppliedinto the vacuum vessel 2 so that a surface of the Ti film is subjectedto a nitriding process. The first pressure is higher than the presetpressure when the TiCl₄ gas and the H₂ gas are supplied into the vacuumvessel 2. For example, the first pressure is 400 Pa. The NH₃ gasnitrides the Ti film to form a titanium nitride (TiN) film on thesurface of the Ti film. In addition, the Ar gas and the H₂ gas, severingas carrier gases of the NH₃ gas, are supplied to uniformly supply a rawmaterial gas onto the wafer and adjust a partial pressure of the NH₃gas. In this embodiment, the nitriding process based on the NH₃ gas isperformed without generating any plasma, but may be performed with aplasmarized NH₃ gas.

After the nitriding process is completed, the second step is initiated.In the second step, for example, as shown in FIG. 5, the supply of theNH₃ gas is stopped and the NH₃ gas existing in the vacuum vessel 2 isdischarged so that the internal pressure of the vacuum vessel 2 ischanged to the second pressure lower than the first pressure. The secondpressure is lower than the first pressure by 100 Pa or more, whichcorresponds to a so-called vacuum state. For example, the secondpressure is the smallest pressure (e.g., 150 Pa) within a pressure rangeset by the pressure adjusting part 23. In this embodiment, the internalpressure of the vacuum vessel 2 is set to the second pressure by thepressure adjusting part 23 based on a control signal provided from thecontrol part 100 according to the processing recipe. In someembodiments, the second pressure may be achieved by maximizing anopening degree of a pressure regulating valve included in the pressureadjusting part 23.

In addition, after the first step is completed, the third step isinitiated to change the internal pressure of the vacuum vessel 2 andsimultaneously, lift up the wafer W from the mounting table 3 by thelifting pins 41. In the third Step, the lifting pins 41 are raised up tothe ascending position. The ascending position may be a position atwhich the wafer W is sufficiently lifted up from the upper surface ofthe mounting table 3 by the lifting pins 41. As an example, a lowersurface of the wafer W may be spaced apart from the upper surface of themounting table 3 by a distance of 0.5 mm or more. In some embodiments,the ascending position may be the same level as that of the transferposition of the wafer.

Subsequently, while maintaining the internal pressure of the vacuumvessel 2 at the second pressure, the supply of the Ar gas and the H₂ gasis stopped and the interior of the vacuum vessel 2 continues to beexhausted for a predetermined period of time. In this way, a first filmforming process (including the Ti film forming process and thesubsequent nitriding process) are completed. Thereafter, second andthird film forming processes (which are similar to the first formingprocess) are initiated. That is to say, the sequence of the first andsecond steps are repeated a multiple number of times (three times, inthis embodiment). A sequence of the second and third film formingprocesses and process conditions thereof are similar to those of thefirst film forming process.

After the first film forming process is completed, for example, as shownin FIG. 5, the second film forming process is initiated in which thelifting pins 41 are lowered down to the descending position and thefirst step as described above is performed. That is to say, the supplyof the TiCl₄ gas, the H₂ gas and the Ar gas is resumed and plasma isgenerated in the vacuum vessel 2 so that a new Ti film is formed on thesurface of the wafer W. Subsequently, the TiCl₄ gas, the H₂ gas and theAr gas are discharged such that the internal pressure of the vacuumvessel 2 is set to the first pressure. And, the supply of the NH₃ gas,the Ar gas and the H₂ gas is resumed to nitride a surface of the new Tifilm. After the first step is completed, the supply of the NH₃ gas isstopped, and the second step of changing the internal pressure of thevacuum vessel 2 to the second pressure lower than the first pressure andsimultaneously the third step of lifting up the wafer W from themounting table 3 by the lifting pins 41 are initiated. Subsequently,while maintaining the internal pressure of the vacuum vessel 2 at thesecond pressure, the supply of the Ar gas and the H₂ gas is stopped andthe interior of the vacuum vessel 2 continues to be exhausted for apredetermined period of time. In this way, the second film formingprocess is completed. The third film forming process (including the Tifilm forming process and a subsequent nitriding process) is performed inthe same manner as that described above.

After the third film forming process is completed, i.e., after thesupply of the Ar gas and the H₂ gas is stopped while maintaining theinternal pressure of the vacuum vessel 2 at the second pressure and theinterior of the vacuum vessel 2 continues to be exhausted for apredetermined period of time, the internal pressure of the vacuum vessel2 is changed to a pressure at the time of unloading the wafer W.Thereafter, the lifting pins 41 are moved up to the transfer positionand subsequently, the gate valve 26 is opened such that the externaltransfer mechanism advances into the vacuum vessel 2. Subsequently, thelifting pins 41 are lowered to deliver the wafer W to the transfermechanism. In this way, the wafer W is unloaded from the vacuum vessel2.

According to the above embodiment, since the internal pressure of thevacuum vessel 2 is changed to the second pressure lower than the firstpressure and simultaneously, the wafer W is lifted up from the mountingtable 3 by the lifting pins 41, it is possible to prevent the wafer W onthe mounting table 3 from sliding due to the pressure variation.

Once the internal pressure of the vacuum vessel 2 is reduced from thefirst pressure to the second pressure, the processing gas introducedbetween the upper surface of the mounting table 3 and the wafer W isdischarged. A flow of the discharged processing gas acts on the wafer Wmounted on the mounting table 3, thus causing sliding of the wafer W.

In contrast, as described in this embodiment, the wafer W is lifted upfrom the mounting table 3 by the lifting pins 41 at the time of changingthe internal pressure so that the wafer W is in point-contact with thetips of the lifting pins 41. As such, a load to be applied to respectivesupport points is increased compared to a case where the wafer W issupported while being in surface-contact with the mounting table, whichresults in an increased static frictional force. Thus, more force isrequired in moving the wafer W. Accordingly, it is possible to preventthe wafer W on the mounting table 3 from sliding even when some degreeof force is exerted on the wafer W due to the pressure variation.

In other words, if the wafer W is lifted up from the mounting table 3 bythe lifting pins 41 at the time of changing the internal pressure of thevacuum vessel 2, the wafer W is less susceptible to the action of theflow of the processing gas, thereby preventing the wafer W on themounting table 3 from sliding. In addition, if an extent of lifting-upof the wafer W from the mounting table 3 is increased, a space betweenthe upper surface of the mounting table 3 and the rear surface of thewafer W is also increased. This allows the wafer W to be less affectedby the flow of the processing gas. Such a method of preventing the waferW from sliding may be applied not only at the time of changing of theinternal pressure but also at the time of significantly adjusting theflow rate of the processing gas.

As described above, the wafer W is prevented from sliding, thuspreventing the occurrence of particles which are caused by the slidingof the wafer W on the mounting table 3. In addition, the wafer isprevented from being too close to the guide ring 32 due to the sliding.This suppresses a deviation in concentration distribution of thefilm-forming gas, which suppresses deterioration in in-plane uniformityof film thickness and also suppresses contamination of the rear surfaceof the wafer W from being partially increased.

In addition, in the above embodiment, since the film forming process isrepeatedly performed a multiple number of times, it is possible toincrease a film thickness of the Ti film while maintaining in-planeuniformity. The present inventors have found that a prolonged period oftime for a single film forming process degrades the in-plane uniformityof film thickness, which makes it hard for the film thickness of the Tifilm to be increased compared to the aforementioned process. The reasonfor this may be that, if the period of time for the single film formingprocess is prolonged, reaction products adhere to an inner wall of thevacuum vessel 2 so that the H₂ gas is consumed by the reaction products.In contrast, in the case where the film forming process is repeated amultiple number of times, the NH₃ gas is supplied for each film formingprocess so that the consumption of the H₂ gas by the reaction productsis suppressed. This suppresses the in-plane uniformity of film thicknessfrom deteriorating and also achieves an increase in thickness of the Tifilm.

When the film forming process is performed a multiple number of times,the pressure variation between the first pressure and the secondpressure is repeated. In this case, the wafer W is prevented fromsliding due to the lifting-up of the wafer W by the lifting pins 41,thus preventing the in-plane uniformity of the film thickness from beinglowered. That is to say, if the wafer W mounted on the mounting table 3slides, an in-plane distribution of the concentration of gas suppliedonto the wafer W for each film forming process is varied, which degradesthe in-plane uniformity of film thickness. However, in this embodiment,since the wafer W is prevented from sliding, there is no possibility ofthe occurrence of such a situation.

Further, as described above, the average surface roughness Ra of thesurface of the mounting table 3 is set to 10 μm or more. This furtherprevents the wafer W from sliding at the time of the pressure variation.Thus, by setting the average surface roughness Ra of the surface of themounting table 3 to 10 μm or more, the static frictional force againstthe wafer W is increased so that more force is required in moving thewafer W.

In addition to the change of the internal pressure of the vacuum vessel2 from the first pressure to the second pressure, the internal pressureof the vacuum vessel 2 may be varied when the TiCl₄ gas and the H₂ gasare introduced into the vacuum vessel 2 and then discharged from thevacuum vessel 2, when the NH₃ gas is introduced into the vacuum vessel2, or the like. Also in these cases, there is a possibility that thewafer W may slide. In addition, the wafer W may slide due to an impactapplied to the wafer W when lifting up the wafer W by the lifting pins41. Accordingly, by making the surface of the mounting table 3 rough, itis possible to prevent the wafer W on the mounting table 3 from slidingwhen any force acts on the wafer W. In a high temperature plasma processperformed in an apparatus such as the aforementioned substrateprocessing apparatus 1, a metal mechanical chuck and an electrostaticchuck cannot be employed. Thus, the method of the present disclosure iseffective in preventing the wafer from sliding during the film formingprocess.

The following description will be made on a timing at which the wafer Wis lifted up by the lifting pins 41. To begin with, there is a need tomount the wafer W on the mounting table 3 before the film-forming gas issupplied. This is because, if the wafer W is lifted up from the mountingtable 3 when the film-forming gas is supplied, an abnormal discharge islikely to occur when the film-forming gas is plasmarized so that a filmmay be formed on the rear surface of the wafer W. This may generateunwanted particles.

Further, there is a need to mount the wafer on the mounting table 3 fora predetermined period of time from the supply of the nitriding gas.This is because the nitriding gas serves also to consume thefilm-forming gas introduced between the upper surface of the mountingtable 3 and the rear surface of the wafer W or the film-forming gasadhering to the interior of the vacuum vessel 2 and, therefore, if thewafer is lifted up from the mounting table 3 in a state where thenitriding gas is insufficiently supplied, the film-forming gas isintroduced into the side of the rear surface of the wafer W, thuscontaminating the rear surface of the wafer.

Accordingly, the third step of lifting up the wafer W from the mountingtable 3 by the lifting pins 41 may be initiated before the internalpressure is changed from the first pressure to the second pressure,after the first step. Herein, the expression “after the first step” mayinclude immediately before the first step is completed. With theabove-described film forming process as an example, the internalpressure of the vacuum vessel 2 may be changed from the first pressureto the second pressure by supplying the NH₃ gas into the vacuum vessel2, followed by raising the lifting pins 41 up to the ascending positionafter a predetermined period of time, followed by stopping the supply ofthe NH₃ gas. The predetermined period of time after the supply of theNH₃ gas refers to a period of time required for the NH₃ gas to consumethe TiCl₄ gas and the H₂ gas introduced between the mounting table 3 andthe wafer W, or the TiCl₄ gas and the H₂ gas adhering to the interior ofthe vacuum vessel 2.

In some embodiments, the mounting table may be installed to be elevatedby an elevating mechanism installed outside of the vacuum vessel, andthe lifting pins as an elevating member may be installed at a fixedheight position. In this configuration, the mounting table is lifted upand down between an ascending position at which the elevating memberprotrudes upward from a surface of the mounting table and a descendingposition equal to or lower than a level of the surface, relative to theelevating member. In some embodiments, the elevating member may beinstalled separately from lifting pins configured to deliver a substratebetween the external transfer mechanism and the mounting table.

Further, the substrate process is not limited to the CVD process but maybe an ALD (Atomic Layer Deposition) process or an etching process.Further, the substrate process may be applied to a process whose processtemperature is 400 degrees C. or less and a process which generates noplasma in a vacuum vessel.

In some embodiments, in the case where the sequence of the first andsecond steps is repeated a multiple number of times during a period oftime between the loading of the substrate into the vacuum vessel and theunloading of the substrate from the vacuum vessel, respective processesin the first and second steps may be different from each other. As anexample, different processing gases and different first and secondpressures may be used in the first and second steps in each of first andsecond film forming processes.

EXAMPLES

Evaluation tests conducted in the context of the present disclosure willbe described below. With the average surface roughness Ra of the surfaceof the mounting table 3 of the above-described substrate processingapparatus 1 set to 10 μm, an amount of sliding of the wafer W when a Tifilm was formed with the sequence shown in FIG. 5 was evaluated (Example1). A type of the processing gas, the first and second pressures and theascending position of the lifting pins 41 in the third step were asdescribed above. The amount of sliding of the wafer W was evaluatedusing a position sensor installed in a transfer vessel (not shown)connected to the vacuum vessel 2 at a timing when the third film formingprocess with the sequence shown in FIG. 5 is completed and subsequentlythe wafer W is unloaded from the vacuum vessel 2. A deviation of thecentral position of the wafer W when the wafer W is transferred onto themounting table 3 was evaluated by measuring the central position of thewafer W using the position sensor. In addition, the central position ofthe wafer W before the wafer W is mounted on the mounting table 3 wasmeasured by the position sensor in advance before the wafer W is loadedinto the vacuum vessel 2. The number of test wafers W was about 400.

In addition, with the average surface roughness Ra of the surface of themounting table 3 set to 2 μm, the same evaluation was conducted when aTi film was formed with the sequence shown in FIG. 5 (Example 2).Further, with the average surface roughness Ra of the surface of themounting table 3 set to 2 μm, the same evaluation was conducted when anNH₃ gas is discharged while mounting the wafer W on the mounting table 3without lifting up the wafer W by the lifting pins 41 in the third step(Comparative Example 1).

The results of these evaluation tests are shown with some of the actualdata schematized in FIG. 6 for Example 1, FIG. 7 for Example 2 and FIG.8 for Comparative Example 1, respectively. In each of FIGS. 6 to 8, ahorizontal axis represents a deviation (mm) in an X direction and avertical axis represents a deviation (mm) in a Y direction. A positionat which the deviations in both the X and Y directions are zerocorresponds to the central position of the surface of the mounting table3, around which central positions of the wafer W are plotted.

From a comparison between Example 2 and Comparative Example 1, it isconfirmed that the deviation is significantly decreased in Example 2,whereas significant sliding having the deviation of 1 mm or more occursfrequently in Comparative Example 1. Thus, it is confirmed that thewafer W on the mounting table 3 is prevented from sliding throughout thefilm forming process by lifting up the wafer W by the lifting pins 41when the internal pressure of the vacuum vessel 2 is changed from thefirst pressure to the second pressure. Thus, the effects of the presentdisclosure were confirmed.

In addition, from a comparison between Example 1 and Example 2, it isconfirmed that the deviation is limited to be less than 0.5 mm inExample 1, which is significantly smaller than that in Example 2. Thus,it is confirmed that the wafer W on the mounting table 3 is furtherprevented from sliding by setting the average surface roughness Ra ofthe surface of the mounting table 3 to 10 μm. Accordingly, it can beunderstood that the sliding of the wafer W which is caused by pressurevariations other than the pressure variation at the time of changing theinternal pressure of the vacuum vessel 2 from the first pressure to thesecond pressure, or when lifting up the wafer W by the lifting pins 41,can be effectively prevented.

According to the present disclosure in some embodiments, in performing aprocess on a substrate by supplying a processing gas onto the substratein a vacuum atmosphere, the processing gas is supplied onto thesubstrate mounted on a mounting table and simultaneously an internalpressure of a vacuum vessel is set to a first pressure. Thereafter, theinternal pressure is changed to a second pressure lower than the firstpressure. Subsequently, the substrate is lifted up from the mountingtable by an elevating member before changing the internal pressure or inparallel with the changing.

When the internal pressure is changed from the first pressure to thesecond pressure, the processing gas introduced between a surface of themounting table and the substrate is discharged and a flow of theprocessing gas acts on the substrate mounted on the surface of themounting table. If the substrate is lifted up from the mounting table bythe elevating member when changing the internal pressure, the substrateis less affected by the flow of the processing gas, thereby preventingthe substrate on the mounting table from sliding during the film formingprocess.

While certain embodiments have been described, these embodiments havebeen presented by way of example only, and are not intended to limit thescope of the disclosures. Indeed, the embodiments described herein maybe embodied in a variety of other forms. Furthermore, various omissions,substitutions and changes in the form of the embodiments describedherein may be made without departing from the spirit of the disclosures.The accompanying claims and their equivalents are intended to cover suchforms or modifications as would fall within the scope and spirit of thedisclosures.

What is claimed is:
 1. A substrate processing apparatus of performing aprocess on a substrate by supplying a processing gas onto the substratein a vacuum atmosphere, comprising: a substrate mounting table installedin a vacuum vessel; a gas supply part configured to supply theprocessing gas into the vacuum vessel; a vacuum-exhausting partconfigured to exhaust the interior of the vacuum vessel; an elevatingmember configured to move up and down between an ascending positiondefined above a surface of the mounting table and a descending positionequal to or lower than a level of the surface of the mounting table andis configured to lift up and down the substrate while holding thesubstrate mounted on the mounting table; and a control part configuredto output a control signal to execute a first step, a second step and athird step, the first step being to supply the processing gas onto thesubstrate mounted on the mounting table and set an internal pressure ofthe vacuum vessel to a first pressure, the second step being to changethe internal pressure to a second pressure lower than the firstpressure, and the third step being to lift up the substrate from themounting table by the elevating member after the first step and beforethe changing the internal pressure or in parallel with the changing. 2.The substrate processing apparatus of claim 1, wherein the secondpressure is the smallest pressure within a setting range of the internalpressure.
 3. The substrate processing apparatus of claim 1, wherein adifference between the second pressure and the first pressure is 100 Paor more.
 4. The substrate processing apparatus of claim 1, wherein thecontrol part outputs the control signal to repeat a sequence of thefirst step and the second step a multiple number of times during aperiod of time from when the substrate is loaded into the vacuum vesseltill when the substrate is unloaded from the vacuum vessel.
 5. Thesubstrate processing apparatus of claim 4, wherein the first stepincludes supplying a film-forming gas used to form a thin film on thesubstrate and subsequently supplying a nitriding gas used to nitride thethin film, and wherein the first pressure is a pressure at the time ofsupplying the nitriding gas.
 6. The substrate processing apparatus ofclaim 1, wherein the elevating member includes three or more pinsconfigured to deliver the substrate between an external transfermechanism and the mounting table.
 7. The substrate processing apparatusof claim 1, wherein an arithmetic average surface roughness of thesurface of the mounting table is 10 μm or more.
 8. A method ofprocessing a substrate by supplying a processing gas onto the substratein a vacuum atmosphere, the method comprising: mounting the substrate ona mounting table installed in a vacuum vessel; supplying the processinggas onto the substrate mounted on the mounting table and setting aninternal pressure of the vacuum vessel to a first pressure;subsequently, changing the internal pressure to a second pressure lowerthan the first pressure; and after the supplying the processing gas,lifting up the substrate from the mounting table by an elevating memberbefore the changing the internal pressure or in parallel with thechanging.
 9. The method of claim 8, comprising repeating a sequence amultiple number of times, the sequence including the supplying theprocessing gas and the changing the internal pressure during a period oftime from when the substrate is loaded into the vacuum vessel till whenthe substrate is unloaded from the vacuum vessel.
 10. The method ofclaim 9, wherein the supplying the processing gas includes supplying afilm-forming gas used to form a thin film on the substrate andsubsequently supplying a nitriding gas used to nitride the thin film,and wherein the first pressure is a pressure at the time of supplyingthe nitriding gas.
 11. A non-transitory computer-readable storage mediumthat stores a computer program used for a substrate processing apparatusof performing a process on a substrate by supplying a processing gasonto the substrate mounted on a mounting table in a vacuum vessel whilemaintaining a vacuum atmosphere, wherein the computer program isorganized with instructions for executing the method of claim 8.